JP3135903B2 - Method for manufacturing reflective article - Google Patents
Method for manufacturing reflective articleInfo
- Publication number
- JP3135903B2 JP3135903B2 JP02122787A JP12278790A JP3135903B2 JP 3135903 B2 JP3135903 B2 JP 3135903B2 JP 02122787 A JP02122787 A JP 02122787A JP 12278790 A JP12278790 A JP 12278790A JP 3135903 B2 JP3135903 B2 JP 3135903B2
- Authority
- JP
- Japan
- Prior art keywords
- metal
- electrode
- mixture
- substance
- space
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
- C23C14/0635—Carbides
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
- C23C14/0641—Nitrides
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
- C23C14/24—Vacuum evaporation
- C23C14/32—Vacuum evaporation by explosion; by evaporation and subsequent ionisation of the vapours, e.g. ion-plating
- C23C14/325—Electric arc evaporation
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/08—Mirrors
- G02B5/0816—Multilayer mirrors, i.e. having two or more reflecting layers
- G02B5/085—Multilayer mirrors, i.e. having two or more reflecting layers at least one of the reflecting layers comprising metal
- G02B5/0875—Multilayer mirrors, i.e. having two or more reflecting layers at least one of the reflecting layers comprising metal the reflecting layers comprising two or more metallic layers
Description
本発明は反射物品の製造方法に関し、特に、表面保護
層を必要としない反射物品の製造方法に関する。The present invention relates to a method for manufacturing a reflective article, and more particularly to a method for manufacturing a reflective article that does not require a surface protective layer.
自動車のヘッドライト用反射体といった、反射面を有
する物品を製造する場合、予備成形された合成樹脂製又
はプラスチック製基材の表面に金属、例えば銀又はアル
ミニウムの反射被膜を設け、こうして形成された反射面
を、やはり合成樹脂材料であってもよい例えば透明ラッ
カーの保護層で被覆することが従来行われていた。 保護被膜を設ける理由は反射層が機械的作用を受けや
すいこと、即ち、接触により容易に摩耗すること及び大
気中で酸化を受けやすく、酸化反応により反射特性に変
化が生じるためである。 したがって、このような反射体を製造するための以前
の方法の主な欠点は、環境上危険で高価な手順でしばし
ば有機溶媒系による保護被膜の塗布を必要とすることで
ある。したがって反射体のコストが比較的高くなる。 また、合成樹脂基材に付与される特定表面の反射率の
程度を制御することがしばしば望まれることも挙げるこ
とができる。このことを従来の方法で行うのは容易では
ない。 さらに、ある材料を表面に蒸着させるアーク法につい
ての技術の現状に言及することができる。アーク溶射法
又はこの種の方法には、付着被膜の均一性に有害な効果
である小滴のはねかけという重要な問題がある。したが
って、小滴のはねかけのないアーク法の利用が長い間求
められていた。When manufacturing an article having a reflective surface, such as a reflector for an automobile headlight, a metal, for example, silver or aluminum reflective coating is provided on the surface of a preformed synthetic resin or plastic substrate, and thus formed. It has been customary to cover the reflective surface with a protective layer of, for example, a transparent lacquer, which may also be a synthetic resin material. The reason for providing the protective coating is that the reflective layer is susceptible to mechanical action, that is, easily abraded by contact and susceptible to oxidation in the atmosphere, and changes in reflection characteristics due to the oxidation reaction. Therefore, a major drawback of previous methods for manufacturing such reflectors is that environmentally hazardous and expensive procedures often require the application of a protective coating with an organic solvent system. Therefore, the cost of the reflector is relatively high. It can also be mentioned that it is often desired to control the degree of reflectance of the specific surface provided to the synthetic resin substrate. This is not easy to do with conventional methods. In addition, reference can be made to the current state of the art of arc methods of depositing certain materials on surfaces. Arc spraying or this type of method has the significant problem of droplet splashing which is a detrimental effect on the uniformity of the deposited coating. Therefore, there has been a long-felt need for the use of an arc method without splashing of droplets.
本発明の第１の目的は反射物品を製造する従来の原理
を発展させて改良された方法を提供することである。 本発明の別の目的は、従来の方法の欠点が解消される
ように反射物品、即ち、反射面を有する物品を製造する
方法を提供することである。 本発明の別の目的は反射面の反射率の制御が改善され
るようにした反射物品の製造方法を提供することであ
る。 本発明のさらに別の目的は、小滴のはねかけという従
来遭遇した問題点を実質的に回避したアーク被覆法を提
供することである。It is a first object of the present invention to provide an improved method that extends the conventional principles of manufacturing reflective articles. It is another object of the present invention to provide a method of manufacturing a reflective article, i.e. an article having a reflective surface, so that the disadvantages of the conventional methods are overcome. It is another object of the present invention to provide a method of manufacturing a reflective article with improved control of the reflectivity of the reflective surface. It is yet another object of the present invention to provide an arc coating method that substantially avoids the previously encountered problem of droplet splashing.
全く意外なことに、蒸着物が化学的に飽和されかつセ
ラミック質となることにより以後の酸化反応を防止する
ようにした条件下で低温アーク真空蒸着法により２種の
金属を組合せた電極から反射被膜を蒸着させると、反射
面に酸化防止保護層を設ける必要のない反射物品、即
ち、反射面をもった物品を製造することが可能であるこ
とが判明した。 本発明によれば、２種の金属として反射率に寄与す
る、即ち、基材上に反射面を形成するのに普通用いられ
る第１の金属及び窒素又は炭素とセラミック化合物を、
即ち、窒化物及び炭化物を生成し得る第２の金属が挙げ
られる。特に、第１の金属は銀又はアルミニウムであっ
てよく、第２の金属はタングステンであってよい。低温
アークは、減圧、好ましくは10-3バール以下、より好ま
しくは10-4バール以下、最も好ましくは10-5以下に維持
された空間に、被覆されるべき基材に対して並列に配置
された混合金属の電極と、例えばやはり混合金属の対向
電極との間に発生され、別の物質、即ち、窒素又は炭素
もしくは窒素又は炭素を与える物質が前記空間に導入さ
れる。 特に、混合金属電極は、２種の金属のうち融点の低い
方の金属の融点未満の温度で２種の金属の混合粉末を熱
間圧縮して凝集構造体に形成されるのがよい。電極中の
２種の金属が互いに合金とならず、実質的に溶け合わな
いことが重要である。 好ましくは、電極は反射性金属とセラミック形成金属
とから成り、第１の金属と第２の金属との重量比は20:8
0乃至80:20、好ましくは25:75乃至45:55である。最良の
結果は30:70乃至50:50の範囲で達成される。 金属が混合金属セラミックとして、即ち、以後の酸化
を防止するように化学的に飽和されたアルミニウム・タ
ングステン炭化物又は窒化物或いは銀，タングステン炭
化物又は窒化物として蒸着される条件下で被膜形成を行
うことの重要性はいくら強調してもしすぎることはな
い。 ここで化学的飽和とは、混合金属被膜の結合能のほと
んどすべてが実際の化学結合により或いは窒素又は炭素
を隙間に閉じ込めていることにより窒素又は炭素で飽和
されていることを意味する。この状態の存在は被膜形成
後の反射率を測定し、被膜を50〜80℃の高温で純酸素雰
囲気にさらし、次いで反射率を再測定することにより簡
単に試験することができる。飽和被膜は当然乍ら反射率
の変化をほとんど示さない。 前記の系を用いて75％を超す反射率を容易に得ること
ができ、この方法は反射面上の保護被膜の必要性とこの
保護被膜に伴う諸欠点とを排除するのでヘッドライト用
反射体の製造に特に有用であることがわかった。 したがって、本発明のこの観点によれば、本発明の方
法は、 （ａ） 高反射性の第１の金属と、セラミックを形成す
るようにした他の物質と反応可能な第２の金属との２種
の金属の非合金混合物から電極を形成する工程、 （ｂ） 排気可能な空間に前記電極と反射被膜が設けら
れるべき基材とを並列に配列する工程、 （ｃ） 前記空間を10-3バール以下の圧力に排気する工
程、 （ｄ） 前記電極と別の電極との間に低電圧アークを発
生させて前記混合物を気化させる工程、 （ｅ） 前記物質を前記空間に導入して前記物質と気化
混合物とを反応させて、前記混合物と前記物質との反射
反応生成物を前記基材に蒸着させる工程、及び （ｆ） 前記混合物の組成、前記圧力及び前記空間への
前記物質の導入を制御することによって前記物質が前記
反応生成物を化学的に飽和して、前記反応生成物に保護
被膜を必要とすることなく前記反応生成物の反射特性の
酸化変化を防ぐようにする工程、 の各工程を含む。 本発明の別の観点によれば、反射被膜は反射率の制御
が可能なように前記方法で形成することができる。窒素
供与体又は酸素供与体の存在下で混合金属電極を用いて
蒸着した被膜の反射率は蒸着被膜の厚さに依存すること
がわかった。被膜は800〜1500Å、好ましくは800〜1000
Åの厚さ範囲で付与することができ、厚さが増大すると
反射率が増大する。 本発明のさらに別の観点において、混合金属粉末を合
金化することなく熱間圧縮により前記の通り形成した電
極を用いることにより、一方の金属が比較的低融点の金
属で他方の金属が高融点の金属である場合にアーク法で
従来発生した小滴のはねかかり傾向が完全に回避できる
ことが判明した。 高融点金属／低融点金属の重量比は80:20乃至20:80、
好ましくは75:35乃至45:55であるのがよく、最良の結果
は70:30乃至50:50の範囲で得られる。高融点金属は例え
ばタングステンとすることができ、低融点金属は例えば
銀又はアルミニウムとすることができる。 理由はまだ完全には解明できてはいないが、本発明の
改良された電極を用いることによりアーク法において従
来発生していた小滴のはねかかりを伴わずに混合金属の
被膜の形成、即ち、反射被膜として前記した種類のセラ
ミック様被膜の製造が可能である。 本発明の前記及びその他の目的、特徴及び利点は極め
て概略的な添付の図面について以下に記載する説明から
容易に明らかであろう。 第１図からわかる通り、銀とタングステンとから成る
一対の熱間圧縮電極11,12が真空ポンプで減圧に排気さ
れた室10に間隔を置いて並列に配置されている。真空ポ
ンプは15に示されている。 アーク発生装置23がロッド24により可動電極12に連結
されてアーク発生のために電極12を電極11に近づけ、次
いで電極12が電極11から引き離され、発生アークにより
電極の混合金属が気化される。直流電圧源25が両電極に
接続され、20〜150ボルトの電圧と30〜150アンペアの電
圧を供給することができる。 基材13はヘッドライト用の合成樹脂（例えばポリウレ
タン又はポリカーボネート）反射体本体であってよく、
排気室内に14に概略示した支持体に載置されている。 被膜を窒化物セラミックとする場合は、タンク21から
窒素を管路16,17及び弁６を経て排気室10に導すること
ができる。 炭化物セラミックを望む場合は、炭素源としてメタン
をタンク22から弁20と管路16,19を経て排気室に導入す
ることができる。 排気室内の雰囲気が窒素とメタンの両方から成る場合
は、もちろん窒化物と炭化物の混合物を形成することが
できる。 第１図の装置は被覆のために既に記載したように操作
される。真空ポンプ15がまず室10を排気し、窒素かメタ
ン或いは両方を室内の微量の空気を除くために室に導入
することができる。所望により窒素又は炭素のポテンシ
ャルをこれらのガスをアルゴンで希釈することにより減
少させることができる。 前記の通り熱間圧縮により形成された電極が室内に位
置付けられ、排気により脱ガスされ、室に窒素及び／又
はメタンが導入される間にアークを（所望により繰返
し）発生させ、例えば第２図に示したヘッドライト用反
射体のプラスチック基材31に反射被膜32を蒸着させるこ
とができる。窒素及び／又はメタンの量は、被膜が炭素
及び／又は窒素で完全に飽和されて、以後に空気中で反
射帯域33に酸化が起こらないように制御される。したが
って保護被膜を設ける必要はない。 この方法では小滴のはねかかりは全てない。 本発明を以下の実施例により説明する。Quite surprisingly, low-temperature arc vacuum deposition reflects from the electrode of the combination of the two metals under conditions in which the deposits are chemically saturated and become ceramic to prevent further oxidation reactions. It has been found that by depositing the coating, it is possible to produce a reflective article that does not require the provision of an antioxidant protective layer on the reflective surface, that is, an article having a reflective surface. According to the present invention, a first metal and a nitrogen or carbon and ceramic compound that contribute to reflectivity as two metals, i.e., commonly used to form a reflective surface on a substrate,
That is, a second metal that can generate nitride and carbide is used. In particular, the first metal may be silver or aluminum and the second metal may be tungsten. The cold arc is arranged in parallel with the substrate to be coated, in a space maintained at reduced pressure, preferably below 10-3 bar, more preferably below 10-4 bar, most preferably below 10-5. Another substance, i.e. nitrogen or carbon or a substance giving nitrogen or carbon, which is generated between the mixed metal electrode and the counter electrode, also of mixed metal, is introduced into the space. In particular, the mixed metal electrode is preferably formed into an aggregated structure by hot-pressing a mixed powder of two metals at a temperature lower than the melting point of the lower melting point metal of the two metals. It is important that the two metals in the electrode do not alloy with each other and do not substantially melt. Preferably, the electrode comprises a reflective metal and a ceramic forming metal, and the weight ratio of the first metal to the second metal is 20: 8.
0 to 80:20, preferably 25:75 to 45:55. Best results are achieved in the range of 30:70 to 50:50. Performing the coating under conditions where the metal is deposited as a mixed metal ceramic, ie as aluminum-tungsten carbide or nitride or silver, tungsten carbide or nitride chemically saturated to prevent subsequent oxidation; The importance of is not overstated. Here, chemical saturation means that almost all of the bonding ability of the mixed metal coating is saturated with nitrogen or carbon by actual chemical bonding or by confining nitrogen or carbon in gaps. The presence of this condition can be easily tested by measuring the reflectivity after coating formation, exposing the coating to a pure oxygen atmosphere at a high temperature of 50-80 ° C, and then re-measuring the reflectivity. Saturated coatings, of course, show little change in reflectivity. Reflectances in excess of 75% can easily be obtained using the system described above, and this method eliminates the need for a protective coating on the reflective surface and the drawbacks associated with this protective coating, so that headlight reflectors It has been found to be particularly useful for the production of Thus, according to this aspect of the invention, the method of the invention comprises the steps of: (a) combining a highly reflective first metal with a second metal capable of reacting with another material adapted to form a ceramic. forming a two electrode from unalloyed mixture of metal, (b) a step of arranging said electrode and the reflective coating should is provided a substrate in parallel to the evacuable space, a (c) the space 10 - Evacuation to a pressure of 3 bar or less, (d) evaporating the mixture by generating a low-voltage arc between the electrode and another electrode, (e) introducing the substance into the space and Reacting a substance and a vaporized mixture to deposit a reflection reaction product of the mixture and the substance on the substrate; and (f) introducing the substance into the composition, the pressure and the space of the mixture. Controlling the reaction of the substance Formed was chemically saturated, comprising the step of the prevent oxidation change of the reflection characteristic of the reaction product, each step of without requiring a protective coating on the reaction product. According to another aspect of the present invention, the reflective coating can be formed by the above method so that the reflectance can be controlled. It has been found that the reflectance of a film deposited using a mixed metal electrode in the presence of a nitrogen donor or an oxygen donor depends on the thickness of the deposited film. The coating is 800-1500800, preferably 800-1000
The thickness can be provided in the range of Å, and the reflectance increases as the thickness increases. In still another aspect of the present invention, by using an electrode formed as described above by hot pressing without alloying the mixed metal powder, one metal has a relatively low melting point and the other metal has a high melting point. It has been found that, when the metal is used, the tendency of the droplets to splash conventionally generated by the arc method can be completely avoided. The weight ratio of high melting point metal / low melting point metal is 80:20 to 20:80,
Preferably it is between 75:35 and 45:55 and the best results are obtained in the range 70:30 to 50:50. The high melting point metal can be, for example, tungsten, and the low melting point metal can be, for example, silver or aluminum. Although the reason has not yet been completely elucidated, the use of the improved electrode of the present invention enables the formation of a mixed metal film without splashing of droplets conventionally generated in the arc method, that is, It is possible to produce ceramic-like coatings of the type described above as reflective coatings. The above and other objects, features and advantages of the present invention will be readily apparent from the description set forth below with reference to the accompanying drawing, which is very schematic. As can be seen from FIG. 1, a pair of hot compression electrodes 11 and 12 made of silver and tungsten are arranged in parallel at intervals in a chamber 10 evacuated to a reduced pressure by a vacuum pump. A vacuum pump is shown at 15. An arc generator 23 is connected to the movable electrode 12 by a rod 24 to bring the electrode 12 closer to the electrode 11 for arc generation, then the electrode 12 is separated from the electrode 11, and the generated metal vaporizes the mixed metal of the electrode. A DC voltage source 25 is connected to both electrodes and can supply a voltage of 20-150 volts and a voltage of 30-150 amps. The substrate 13 may be a synthetic resin (for example, polyurethane or polycarbonate) reflector body for a headlight,
It is placed in a support, shown schematically at 14, in the exhaust chamber. When the coating is made of nitride ceramic, nitrogen can be introduced from the tank 21 to the exhaust chamber 10 via the lines 16 and 17 and the valve 6. If a carbide ceramic is desired, methane as a carbon source can be introduced into the exhaust chamber from tank 22 via valve 20 and lines 16,19. If the atmosphere in the exhaust chamber consists of both nitrogen and methane, a mixture of nitrides and carbides can of course be formed. The apparatus of FIG. 1 operates as described above for coating. A vacuum pump 15 first evacuates chamber 10 and nitrogen or methane or both can be introduced into the chamber to remove traces of air in the chamber. If desired, the nitrogen or carbon potential can be reduced by diluting these gases with argon. An electrode formed by hot compression as described above is positioned in the chamber, degassed by exhaust, and (optionally repeated) generating an arc while introducing nitrogen and / or methane into the chamber, eg, FIG. The reflective coating 32 can be deposited on the plastic substrate 31 of the headlight reflector shown in FIG. The amount of nitrogen and / or methane is controlled so that the coating is completely saturated with carbon and / or nitrogen so that no further oxidation takes place in the reflection zone 33 in air. Therefore, there is no need to provide a protective coating. With this method, there is no splashing of the droplets. The invention is illustrated by the following example.
実施例Ｉ 電極11,12を銀粉末30重量％とタングステン粉末70重
量％の混合物から熱間圧縮によりつくった。いずれも粒
径が50〜100ミクロンの銀粉末とタングステン粉末を充
分に混合してから熱間圧縮用鋳型に入れた。 これらの粉末を圧力100バール、温度900℃で熱間圧縮
した。 被膜形成は第１図に概略示した装置を用い、アーク電
圧100ボルト、電流40〜80アンペアを用いて行った。窒
素を室に供給し、厚さ100Åの混合窒化物の被膜をポリ
ウレタン基材に蒸着した。反射率を純酸化雰囲気で75℃
及び80℃で測定し、反射率の変化は認められなかった。 室にメタンを導入した場合も同様の結果が得られた。 実施例II 銀の代わりにアルミニウム粒子を用いた外は実施例Ｉ
の工程に従った。熱間圧縮は600℃で実施した。この実
施例では熱間圧縮をアルゴン雰囲気下で行った。 得られたヘッドライト用反射体は75％を超える反射率
を有し、反射面に保護被膜を必要としなかった。Example I The electrodes 11, 12 were made by hot pressing from a mixture of 30% by weight of silver powder and 70% by weight of tungsten powder. In each case, silver powder and tungsten powder each having a particle size of 50 to 100 microns were sufficiently mixed and then placed in a hot compression mold. These powders were hot pressed at a pressure of 100 bar and a temperature of 900 ° C. The coating was formed using the apparatus shown schematically in FIG. 1 using an arc voltage of 100 volts and a current of 40-80 amps. Nitrogen was supplied to the chamber, and a 100-mm-thick mixed nitride film was deposited on the polyurethane substrate. 75 ° C reflectivity in pure oxidizing atmosphere
And at 80 ° C., no change in reflectance was observed. Similar results were obtained when methane was introduced into the chamber. Example II Example I except aluminum particles were used instead of silver
Was followed. Hot pressing was performed at 600 ° C. In this embodiment, hot compression was performed in an argon atmosphere. The resulting headlight reflector had a reflectivity of greater than 75% and did not require a protective coating on the reflective surface.
第１図は本発明の被膜形成を説明する図であり、第２図
は本発明の方法によって製造されたヘッドライト用反射
体の横断面図である。 10……真空室、11,12……電極、13……基材、14……支
持体、23……アーク発生装置、30……ヘッドライト用反
射体、31……プラスチック基材、32……反射被膜、33…
…反射帯域。FIG. 1 is a view for explaining the film formation of the present invention, and FIG. 2 is a cross-sectional view of a headlight reflector manufactured by the method of the present invention. 10 ... Vacuum chamber, 11,12 ... Electrode, 13 ... Base, 14 ... Support, 23 ... Arc generator, 30 ... Reflector for headlight, 31 ... Plastic base, 32 ... … Reflective coating, 33…
... reflection band.
───────────────────────────────────────────────────── フロントページの続き (51)Int.Cl.7 識別記号 ＦＩ Ｆ２１Ｖ 7/22 Ｆ２１Ｍ 3/08 Ｚ Ｇ０２Ｂ 5/08 (56)参考文献 特開 昭60−255973（ＪＰ，Ａ) 特開 昭58−150901（ＪＰ，Ａ) 特開 昭63−192856（ＪＰ，Ａ) 特表 昭63−502288（ＪＰ，Ａ) (58)調査した分野(Int.Cl.7，ＤＢ名) C23C 14/00 - 14/58 F21S 8/10 F21V 7/00 F21V 7/22 G02B 5/08 ────────────────────────────────────────────────── ─── Continued on the front page (51) Int.Cl. 7 Identification symbol FI F21V 7/22 F21M 3/08 Z G02B 5/08 (56) References JP-A-60-255973 (JP, A) JP-A Sho 58-150901 (JP, A) JP-A-63-192856 (JP, A) JP-A-63-502288 (JP, A) (58) Fields investigated (Int. Cl. 7 , DB name) C23C 14/00 -14/58 F21S 8/10 F21V 7/00 F21V 7/22 G02B 5/08
Claims (21)
るように他の物質と反応可能な第２の金属との２種の金
属の非合金混合物から電極を形成する工程、 （ｂ） 排気可能な空間に前記電極と反射被膜が設けら
れるべき基材とを並列に配置すること、 （ｃ） 前記空間を10-3バール以下の圧力に排気する工
程、 （ｄ） 前記電極と別の電極との間に低電圧アークを発
生させて前記混合物を気化させる工程、 （ｅ） 前記物質を前記空間に導入して前記物質と気化
混合物とを反応させ、前記混合物と前記物質との反射反
応生成物を前記基材に蒸着させる工程、及び （ｆ） 前記混合物の組成、前記圧力及び前記空間への
前記物質の導入を制御することによって前記物質が前記
反応生成物を化学的に飽和して、前記反応生成物に保護
被膜を必要とすることなく前記反応生成物の反射特性の
酸化変化を防ぐようにする工程、 の各工程を含む反射体の製造方法。1. A method for manufacturing a reflector, comprising: (a) a first metal having high reflectivity and a second metal capable of reacting with another substance to form a ceramic. Forming an electrode from a non-alloy mixture of (b) arranging the electrode and a substrate on which a reflective coating is to be provided in parallel in an evacuable space; (c) setting the space to 10 -3 bar or less. Evacuation to pressure; (d) evaporating the mixture by generating a low voltage arc between the electrode and another electrode; (e) introducing the substance into the space to evaporate the substance and the vaporized mixture. Reacting the mixture with the mixture and depositing a reflection reaction product of the mixture and the substance on the substrate; and (f) controlling the composition of the mixture, the pressure, and the introduction of the substance into the space. The substance chemically saturates the reaction product The process of the prevent oxidation change of the reflection properties of the reaction products, the manufacturing method of the reflector, including the steps of without requiring a protective coating on the reaction product.
くとも75％の反射率が得られるように前記混合物の組
成、前記圧力、前記空間への前記物質の導入及び前記基
材上の前記反応生成物の厚さを選択する請求項１記載の
方法。2. The composition of the mixture, the pressure, the introduction of the substance into the space, and the reaction on the substrate such that a reflectance of at least 75% is obtained by the reaction product on the substrate. The method of claim 1 wherein the thickness of the product is selected.
記載の方法。3. The method of claim 2, wherein said thickness is between 800 and 1500 degrees.
The described method.
れらの混合物から成る群から選択される請求項２記載の
方法。4. The method of claim 2, wherein said first metal is selected from the group consisting of silver, aluminum and mixtures thereof.
化物を生成可能な金属である請求項４記載の方法。5. The method according to claim 4, wherein said second metal is a metal capable of forming ceramic nitride or carbide.
項５記載の方法。6. The method of claim 5, wherein said second metal is tungsten.
生成物が窒化物又は炭化物である請求項６記載の方法。7. The method according to claim 6, wherein said substance is nitrogen or carbon, and said reaction product is nitride or carbide.
ンを導入することによって生成される請求項６記載の方
法。8. The method according to claim 6, wherein said substance is carbon and is produced by introducing methane into said space.
極中に80:20乃至20:80の重量比で存在する請求項６記載
の方法。9. The method of claim 6, wherein said first metal and said second metal are present in said electrode in a weight ratio of 80:20 to 20:80.
項９記載の方法。10. The method of claim 9, wherein said weight ratio is between 30:70 and 50:50.
の粉末を混合して粉末混合物を形成し、この粉末混合物
を前記各金属のうち融点の低い方の金属の融点未満の温
度で熱間圧縮することによって形成される請求項１記載
の方法。11. The electrode comprises a powder mixture formed by mixing powders of the first and second metals, and forming the powder mixture at a temperature lower than the melting point of the lower melting point metal of the metals. The method of claim 1 formed by hot pressing at
ッドライト用反射体。12. A reflector for a headlight manufactured by the method according to claim 1.
ねかかりを防止する方法であり、 （ａ） 低融点の第１の金属であって、この金属により
前記基材に近接してアークを発生させると前記基材上へ
小滴となってはねかかりやすい前記第１の金属と高融点
の第２の金属との２種の金属の非合金混合物から電極を
形成する工程、 （ｂ） 排気可能な空間に前記電極と反射被膜が設けら
れるべき基材とを並列に配置する工程、 （ｃ） 前記空間を10-3バール以下の圧力に排気する工
程、及び （ｄ） 前記電極と対向電極との間に低電圧アークを発
生させて前記混合物を気化させ、前記基材に前記混合物
の被膜を蒸着させることにより前記電極からの小滴が前
記基材上へはねかかるのを防ぐ工程、 の各工程を含む前記方法。13. A method for preventing splashing of small droplets when a base material is coated by arc vapor deposition, comprising: (a) a first metal having a low melting point, said metal being close to said base material by said metal; Forming an electrode from a non-alloyed mixture of two metals, the first metal and the second metal having a high melting point, which are liable to become small droplets on the substrate when an arc is generated. (B) arranging the electrode and the base material on which the reflective coating is to be provided in parallel in a evacuable space; (c) evacuating the space to a pressure of 10 −3 bar or less; By generating a low-voltage arc between the electrode and the counter electrode to vaporize the mixture, and depositing a film of the mixture on the substrate, droplets from the electrode splash onto the substrate. The method comprising the steps of:
これらの混合物から成る群から選択される請求項13記載
の方法。14. The method of claim 13, wherein said first metal is selected from the group consisting of silver, aluminum and mixtures thereof.
炭化物反応生成物を生成可能な金属である請求項14記載
の方法。15. The method of claim 14, wherein said second metal is a metal capable of producing a ceramic nitride or carbide reaction product.
求項15記載の方法。16. The method according to claim 15, wherein said second metal is tungsten.
応生成物が窒化物又は炭化物である請求項16記載の方
法。17. The method according to claim 16, wherein said substance is nitrogen or carbon and said reaction product is a nitride or carbide.
タンを導入することによって生成される請求項16記載の
方法。18. The method according to claim 16, wherein said substance is carbon and produced by introducing methane into said space.
電極中に80:20乃至20:80の重量比で存在する請求項16記
載の方法。19. The method of claim 16, wherein said first metal and said second metal are present in said electrode in a weight ratio of 80:20 to 20:80.
項19記載の方法。20. The method of claim 19, wherein said weight ratio is between 30:70 and 50:50.
の粉末を混合して粉末混合物を形成し、この粉末混合物
を前記各金属のうち融点の低い方の金属の融点未満の温
度で熱間圧縮することによって形成される請求項13記載
の方法。21. A method according to claim 21, wherein said metal mixes powders of said first and second metals to form a powder mixture, and the powder mixture is heated to a temperature lower than the melting point of the lower melting point metal of said metals. 14. The method of claim 13, wherein the method is formed by hot compacting.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US07/437,834 US5045344A (en) | 1989-11-16 | 1989-11-16 | Method of making reflective articles |
| US437834 | 1989-11-16 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH03162564A JPH03162564A (en) | 1991-07-12 |
| JP3135903B2 true JP3135903B2 (en) | 2001-02-19 |
Family
ID=23738094
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP02122787A Expired - Fee Related JP3135903B2 (en) | 1989-11-16 | 1990-05-11 | Method for manufacturing reflective article |
Country Status (2)
| Country | Link |
|---|---|
| US (1) | US5045344A (en) |
| JP (1) | JP3135903B2 (en) |
Families Citing this family (14)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5536409A (en) * | 1994-10-25 | 1996-07-16 | Citec International Incorporated | Water treatment system |
| US6009829A (en) * | 1997-08-30 | 2000-01-04 | United Technologies Corporation | Apparatus for driving the arc in a cathodic arc coater |
| US5932078A (en) * | 1997-08-30 | 1999-08-03 | United Technologies Corporation | Cathodic arc vapor deposition apparatus |
| US6036828A (en) * | 1997-08-30 | 2000-03-14 | United Technologies Corporation | Apparatus for steering the arc in a cathodic arc coater |
| US5972185A (en) * | 1997-08-30 | 1999-10-26 | United Technologies Corporation | Cathodic arc vapor deposition apparatus (annular cathode) |
| US6520650B2 (en) | 1999-02-08 | 2003-02-18 | Valeo Sylvania L.C.C. | Lamp reflector with a barrier coating of a plasma polymer |
| US6355723B1 (en) | 2000-06-22 | 2002-03-12 | General Electric Co. | Dark colored thermoplastic compositions, articles molded therefrom, and article preparation methods |
| US6561679B1 (en) | 2000-11-20 | 2003-05-13 | Visteon Global Technologies, Inc. | Decorative coating for exterior automotive lighting applications |
| US7329462B2 (en) * | 2002-08-23 | 2008-02-12 | General Electric Company | Reflective article and method for the preparation thereof |
| US7132149B2 (en) * | 2002-08-23 | 2006-11-07 | General Electric Company | Data storage medium and method for the preparation thereof |
| US7128959B2 (en) * | 2002-08-23 | 2006-10-31 | General Electric Company | Reflective article and method for the preparation thereof |
| US7300742B2 (en) * | 2002-08-23 | 2007-11-27 | General Electric Company | Data storage medium and method for the preparation thereof |
| US8916032B2 (en) * | 2007-10-02 | 2014-12-23 | Roger Wen Yi Hsu | Light emitting diode vacuum coating by magnetized mask |
| JP5607634B2 (en) † | 2008-09-18 | 2014-10-15 | コーニンクレッカ フィリップス エヌ ヴェ | Lighting unit and vehicle headlamp |
Family Cites Families (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2946700A (en) * | 1957-12-24 | 1960-07-26 | Crucible Steel Co America | Production of infiltrated composites |
| SE435297B (en) * | 1975-08-22 | 1984-09-17 | Bosch Gmbh Robert | OPTICAL REFLECTORS MANUFACTURED BY COATING A REFLECTOR |
| US4337607A (en) * | 1979-04-23 | 1982-07-06 | Giovanni Boschetti | Tongue and groove boards with spacers permitting expansion, and method of making the same |
| US4407871A (en) * | 1980-03-25 | 1983-10-04 | Ex-Cell-O Corporation | Vacuum metallized dielectric substrates and method of making same |
| US4540596A (en) * | 1983-05-06 | 1985-09-10 | Smith International, Inc. | Method of producing thin, hard coating |
| US4929322A (en) * | 1985-09-30 | 1990-05-29 | Union Carbide Corporation | Apparatus and process for arc vapor depositing a coating in an evacuated chamber |
| US4842710A (en) * | 1987-03-23 | 1989-06-27 | Siemens Aktiengesellschaft | Method of making mixed nitride films with at least two metals |
-
1989
- 1989-11-16 US US07/437,834 patent/US5045344A/en not_active Expired - Lifetime
-
1990
- 1990-05-11 JP JP02122787A patent/JP3135903B2/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| US5045344A (en) | 1991-09-03 |
| JPH03162564A (en) | 1991-07-12 |
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